Case Study: Johnson Controls achieves world‑class scrap reduction, $600K annual quality cost savings and productivity gains with Epicor Mattec MES

Epicor Mattec MES drives continuous improvement

Johnson Controls’ Florence, KY plant, a manufacturer of plastic battery cases for automotive OEMs and aftermarket customers, faced challenges managing 44 injection‑molding machines with manual, once‑per‑shift data collection that prevented true Statistical Process Control (SPC) and hindered efforts to reduce scrap, increase machine utilization, and reach its “38‑second” production efficiency goal.

By implementing Epicor Mattec MES for real‑time production monitoring and SPC, the plant automated data capture across roughly 250–300 machines and processes, enabling rapid control‑limit setup, proactive maintenance, and faster troubleshooting. Results include scrap reduced to 1.37% (start‑up scrap down 23% and running scrap down 27% over seven years), machine downtime cut 3.1%, conversion cost improved 13%, productivity up 8%, a 50% reduction in changeover time, $600,000 annual savings in cost‑of‑quality, and progress toward the 38‑second target (double‑part cycle time reduced from 54s to 47.5s).

Johnson Controls

Dave Rose

Quality Engineer, Johnson Controls